REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

id031300145100

Special service tool (SST)

49 T025 001   Boot clamp crimpers

Replacement part

Oil and chemical type

Caution

•  Do not allow a magnetized tool such as a magnetized screwdriver to come into contact with the ABS sensor rotor. If the ABS sensor rotor becomes magnetized, it will be unable to read the ABS wheel-speed sensor waveform correctly resulting in an ABS system malfunction to be determined and the inability to perform ABS control. If a magnetized object comes into contact with the ABS sensor rotor, it will be necessary to newly replace the rear drive shaft (ABS sensor rotor).

1.  Disassemble in the order shown in the figure.

2.  Assemble in the reverse order of disassembly.

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1	Boot band (differential side) (See Boot Band (Differential Side) Disassembly Note.) (See Boot Band (Differential Side) Assembly Note.)
2	Outer ring (See Outer Ring Disassembly Note.) (See Outer Ring Assembly Note.)
3	Snap ring (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
4	Tripod joint (See Snap Ring, Tripod Joint Disassembly Note.) (See Tripod Joint, Snap Ring Assembly Note.)
5	Boot (differential side) (See Boot (Differential Side) Disassembly Note.) (See Boot (Differential Side) Assembly Note.)
6	Boot band (wheel side) (See Boot Band (Wheel Side) Disassembly Note.) (See Boot Band (Wheel Side) Assembly Note.)
7	Boot (wheel side) (See Boot (Wheel Side) Disassembly Note.) (See Boot (Wheel Side) Assembly Note.)
8	Rear drive shaft joint component

Boot Band (Differential Side) Disassembly Note

1.  Using a flat chisel and hammer, lightly tap the lever of the boot band to disconnect the lock clip.

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2.  Remove the boot band using pliers.

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Outer Ring Disassembly Note

1.  Place alignment marks on the shaft and outer ring.

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Caution

•  To prevent damage to parts, use paint instead of a punch or similar tool to place alignment marks.

2.  Remove the outer ring from the shaft.

3.  Wipe off grease on the outer ring using a cloth.

Snap Ring, Tripod Joint Disassembly Note

Caution

•  To prevent damage to parts, use paint instead of a punch or similar tool to place alignment marks.

1.  Place alignment marks on the shaft and tripod joint.

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2.  Remove the snap ring using snap ring pliers.

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Caution

•  Be careful not to scratch the roller area when using a hammer and urethane bar or equivalent. Otherwise, the part could be damaged.

Note

•  If the tripod joint cannot be removed from the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and remove the tripod joint from the shaft.

3.  Remove the tripod joint from the shaft.

4.  Wipe off grease on the shaft and tripod joint using a cloth.

Boot (Differential Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (differential side).

3.  Wipe off grease on the boot (differential side) using a cloth.

Boot Band (Wheel Side) Disassembly Note

1.  Remove the boot band using end clamp pliers.

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Boot (Wheel Side) Disassembly Note

1.  Wrap vinyl tape around the spline area of the shaft to prevent damage to the boot.

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2.  Remove the boot (wheel side).

3.  Wipe off grease on the boot (wheel side) and ball joint using a cloth.

Boot (Wheel Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (wheel side) with the vinyl tape left wrapped around the spline area of the shaft.

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

2.  Apply the specified grease to the ball joint and boot (wheel side).

3.  Assemble the boot (wheel side) to the ball joint.

Boot Band (Wheel Side) Assembly Note

1.  Adjust opening A of the SST to the standard by rotating the adjustment bolt.

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2.  Crimp the boot band using the SST.

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3.  Verify that crimp B of the boot band is within the standard.

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•  If width B of the crimp exceeds the standard, reduce opening width A of the SST and crimp the boot band again.

•  If crimp B is less than the standard, increase opening A of the SST and crimp a new boot band.

4.  Verify that the boot band does not protrude from the band assembly area.

•  If the boot band protrudes from the assembly area, replace it with a new one and repeat Steps 1 to 3.

Boot (Differential Side) Assembly Note

Note

•  The boot shapes on the wheel side and the differential side are different. Do not assemble the wrong boot by mistake.

1.  Insert the shaft through the boot (differential side) with vinyl tape left wrapped around the spline area of the shaft.

2.  Remove the vinyl tape wrapped around the spline of the shaft.

Tripod Joint, Snap Ring Assembly Note

1.  Assemble the tripod joint with the shaft and tripod joint alignment marks aligned.

Caution

•  Be careful not to scratch the roller area when using a hammer and urethane bar or equivalent. Otherwise, the part could be damaged.

Note

•  If the tripod joint cannot be assembled to the shaft, lightly tap the tripod joint evenly using a hammer and urethane bar or equivalent, and assemble the tripod joint to the shaft.

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2.  Assemble a new snap ring using snap ring pliers.

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3.  Verify that the snap ring is assembled correctly in the groove of the shaft.

Outer Ring Assembly Note

1.  Apply the specified grease to the outer ring and boot (differential side).

Note

•  Apply the grease from the tube. Do not touch the grease directly with your hand.

2.  Assemble the outer ring with the alignment marks on the shaft and outer ring aligned.

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3.  Assemble the boot (differential side) to the outer ring.

4.  Set the rear drive shaft to the standard length.

5.  Release any trapped air from the boot by carefully lifting up the small end of the boot with a screwdriver wrapped in a clean rag.

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Note

•  Be careful not to damage the boot. Verify that there is no grease leakage.

•  If the boot is deformed, it may not be possible to perform the full-length adjustment of the rear drive shaft.

6.  Verify that the rear drive shaft length is within the standard when the inside of the boot is at atmospheric pressure.

•  If not within the standard, repeat from Step 4.

Boot Band (Differential Side) Assembly Note

Warning

•  Your hands could be injured while assembling the boot band. Therefore always wear gloves.

1.  Apply rust prevention oil to the inside of the boot band.

2.  Lock the boot band against rotation using an appropriate tool as shown in the figure.

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3.  Using a pair of pliers, grip the lever at the base (fulcrum point) and rotate it in the direction of the arrow.

Caution

•  Do not put the boot band back to its original position after bending it using pliers because it will damage the boot band.

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4.  Hold the bent lever using a hand and secure it temporarily by pinching the lock clip using pliers.

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Caution

•  If the lever springs back, press it back in no more than 3 times to prevent damage to the boot band.

5.  Lightly press the lock clip using a hammer so that the clearance of the lock clip is 1 mm {0.04 in} or less.

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•  If there is any malfunction, replace with a new boot band.

6.  Verify that the clearance between the boot band and boot band lever is 1 mm {0.04 in} or less.

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•  If there is any malfunction, replace with a new boot band.

7.  After assembling the boot band, perform the following verification.

•  The boot band does not protrude from the band assembly area.

•  The lever is not deformed.

•  The boot and boot band are not damaged.

•  The boot is not damaged.